US11404838B2 - Preformed solder-in-pin system - Google Patents
Preformed solder-in-pin system Download PDFInfo
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- US11404838B2 US11404838B2 US17/321,745 US202117321745A US11404838B2 US 11404838 B2 US11404838 B2 US 11404838B2 US 202117321745 A US202117321745 A US 202117321745A US 11404838 B2 US11404838 B2 US 11404838B2
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- preformed solder
- connector
- guide fixture
- pins
- cavity
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/51—Fixed connections for rigid printed circuits or like structures
- H01R12/55—Fixed connections for rigid printed circuits or like structures characterised by the terminals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/04—Pins or blades for co-operation with sockets
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
- H01R24/86—Parallel contacts arranged about a common axis
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/02—Soldered or welded connections
- H01R4/023—Soldered or welded connections between cables or wires and terminals
- H01R4/024—Soldered or welded connections between cables or wires and terminals comprising preapplied solder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0235—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for applying solder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0263—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections for positioning or holding parts during soldering or welding process
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
- H05K3/4007—Surface contacts, e.g. bumps
- H05K3/4015—Surface contacts, e.g. bumps using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/36—Electric or electronic devices
- B23K2101/38—Conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R2107/00—Four or more poles
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10295—Metallic connector elements partly mounted in a hole of the PCB
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10431—Details of mounted components
- H05K2201/1059—Connections made by press-fit insertion
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/02—Details related to mechanical or acoustic processing, e.g. drilling, punching, cutting, using ultrasound
- H05K2203/0278—Flat pressure, e.g. for connecting terminals with anisotropic conductive adhesive
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/04—Soldering or other types of metallurgic bonding
- H05K2203/0415—Small preforms other than balls, e.g. discs, cylinders or pillars
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/30—Assembling printed circuits with electric components, e.g. with resistor
- H05K3/32—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits
- H05K3/34—Assembling printed circuits with electric components, e.g. with resistor electrically connecting electric components or wires to printed circuits by soldering
- H05K3/3457—Solder materials or compositions; Methods of application thereof
- H05K3/3478—Applying solder preforms; Transferring prefabricated solder patterns
Definitions
- Example embodiments in general relate to a preformed solder-in-pin system for use with electrical connectors.
- Solder-type connectors have been used for many years to serve as electrical interfaces between circuits and components. Such connectors typically have multiple conductive connector pins or sockets that fit within a housing to provide a seal and structural support for the pins (or sockets) that mate with corresponding sockets or pins in a mating connector.
- connection of wires to the connector pins is made is with wires soldered to cavities or “cups” in the backs of the pins or sockets.
- solder is typically melted into the cavities and then later melted again to install the wires, with each step typically done by hand.
- every manual step such as melting solder into the pins and then hand soldering wires into the pins, can be time consuming, and further, each time solder is heated, it can be degraded.
- An example embodiment is directed to a preformed solder-in-pin system.
- the preformed solder-in-pin system includes a connector pin with a preformed solder member positioned within a cavity formed at one end of the connector pin.
- the connector pin generally comprises a first end and a second end, with an elongated portion proximate the second end, the elongated portion typically designed to mate with another connector.
- the connector pin may be made of any metal with suitable electrical and mechanical properties for use in connectors, such as copper, brass, steel, palladium, or alloys of various metals.
- the connector pin may be made of a single metal, an alloy, or have an alloy base (such as a copper alloy base) and be plated with another metal, such as gold or nickel.
- the connector pin may comprise an upper portion proximate the first end.
- the connector pin may further comprise a cavity extending into the first end toward the second end, the cavity comprising an opening proximate the first end.
- the upper portion may be configured to receive a preformed solder member within the cavity, the solder member typically being pressed into place to tightly and completely fill the cavity, without having been first melted. Accordingly, it is only necessary to melt the solder once, which can limit degradation of the solder compared to solder that is melted multiple times.
- FIG. 1A is a perspective view of a preformed solder-in-pin system in accordance with an example embodiment with a preformed solder member shown prior to insertion in the connector pin.
- FIG. 1B is a perspective view of a preformed solder-in-pin system in accordance with an example embodiment with a preformed solder member shown installed in the connector pin.
- FIG. 1C is a perspective view of a preformed solder-in-pin system in accordance with an example embodiment with a preformed solder member shown installed and pressed into the connector pin.
- FIG. 1D is a top view of a preformed solder-in-pin system in accordance with an example embodiment with a preformed solder member shown installed and pressed into the connector pin.
- FIG. 2 is a perspective view of a preformed solder member in accordance with an example embodiment.
- FIG. 3A is a sectional view of a connector pin in accordance with an example embodiment.
- FIG. 3B is a sectional view of a connector pin in accordance with an example embodiment with a preformed solder member shown installed in the connector pin.
- FIG. 3C is a sectional view of a connector pin in accordance with an example embodiment with a preformed solder member shown installed and pressed into the connector pin.
- FIG. 3D is a sectional view of a female-type connector pin in accordance with an example embodiment.
- FIG. 4A is a sectional view of a connector pin in accordance with an example embodiment with a preformed solder member shown installed in the connector pin prior to being pressed into a cavity.
- FIG. 4B is a sectional view of a connector pin in accordance with an example embodiment with a preformed solder member shown installed and pressed into the connector pin.
- FIG. 5 is a perspective view of a connector grommet with multiple connector pins installed in accordance with an example embodiment.
- FIG. 6 is a perspective view of three connector grommets positioned in a connector holder in accordance with an example embodiment.
- FIG. 7 is a perspective view of a guide fixture in accordance with an example embodiment.
- FIG. 8 is a perspective view of a guide fixture positioned over a connector holder in accordance with an example embodiment.
- FIG. 9 is a top view of a guide fixture positioned over a connector holder with preformed solder members on the guide fixture in accordance with an example embodiment.
- FIG. 10 is another top view of a guide fixture positioned over a connector holder with preformed solder members on the guide fixture in accordance with an example embodiment.
- FIG. 11 is a sectional view of a guide fixture positioned over a connector grommet with preformed solder members accordance with an example embodiment.
- FIG. 12 is a sectional view of a connector grommet with multiple connector pins and preformed solder members installed in accordance with an example embodiment, with a press plate.
- FIG. 13 is a sectional view of a connector grommet with multiple connector pins and preformed solder members installed and pressed into place, in accordance with an example embodiment.
- FIG. 14 is a perspective view of a connector grommet with multiple connector pins with wires installed in accordance with an example embodiment.
- An example connector pin 10 with preformed solder member 30 generally comprises a first end 12 and a second end 14 of the pin, with an elongated portion 16 proximate the second end 14 , the elongated portion 16 typically of the configuration to mate with another connector.
- the connector pin 10 may be made of any metal with suitable electrical and mechanical properties for use in connectors, such as copper, brass, steel, palladium, or alloys of various metals.
- the connector pin 10 may be made of a single metal, an alloy, or have an alloy base (such as a copper alloy base) and be plated with another metal, such as gold or nickel.
- the connector pin 10 may comprise an upper portion 18 proximate the first end 12 .
- the upper portion 18 may be configured to receive a wire.
- the connector pin 10 may further comprise a cavity 20 extending into the first end 12 toward the second end 14 , the cavity 20 comprising an opening 22 proximate the first end 12 .
- the connector pin may also include a preformed solder member positioned in the cavity 20 , the preformed solder member 30 having a solder member first end 32 , a solder member second end 34 , and a sidewall 36 that fits within the cavity.
- the preformed solder member 30 is not melted into the cavity 20 , but pressed into it, so that it takes the shape of, and substantially fills, the cavity 20 . Further, because it is pressed in with considerable force, and has a volume that is close to the exact volume of the cavity 20 , when the solder member 30 is installed, the cavity is substantially free of voids.
- the elongated portion 16 of the connector pin may be either a male or female type connector element, and may thus mate with a complementary connector type.
- the connector pin's elongated portion 16 may comprise a first cylindrical section and the upper portion 18 may comprise a second cylindrical section, wherein the second cylindrical section has a greater diameter than the first cylindrical section.
- the first cylindrical section may comprise substantially the entire length of the elongated portion. It is also possible for the upper portion 18 and the elongated portion 16 to have the same diameter, which is often (but not always) the case with female type connector pins.
- the opening 22 is the only opening in the upper portion 18 of the connector pin 10 .
- the cavity 20 may also comprise a main portion 24 that is cylindrical and coaxial with the second cylindrical section.
- the end of the cavity 20 opposite the opening may have different shapes, as desired by design or as a result of how the cavity 20 is formed.
- the preformed solder member 30 will take the shape of the cavity 20 (including the taper portion), and fill it, when the solder member 30 is inserted and pressed into place. To accomplish this filling, the preformed solder member 30 will preferably have the same volume as the cavity 20 , regardless of shape.
- the first end 12 of connector pin 10 may comprise an upper surface 19 that is ring-shaped and planar, which will result when the cavity 20 is drilled in the center of the connector pin 10 , in a coaxial manner.
- the preformed solder member 30 When the preformed solder member 30 is pressed into the cavity 20 , it may comprise a first surface 38 that is substantially coplanar with the upper surface 19 of the connector pin 10 , proximate the first end 12 of the connector pin 10 .
- the cavity 20 of the connector pin may be substantially free of voids once the preformed solder member 30 is inserted and installed. Air trapped within cavities in solder pins is undesirable, because the air can expand rapidly when the solder is heated and melted. This usually necessitates placement of a small weep hole toward the bottom of a solder cavity to allow air to escape. A weep hole is not necessary with the example embodiments described herein.
- This method can take the place of, for example, using a pick-and-place machine for initial insertion of solder preforms into connector pins.
- multiple connector pins can be installed into a connector grommet 50 , of the type that will hold the pins in position when a connector is fully assembled.
- the method involves using a connector holder 40 and a guide fixture 70 that is aligned just above the connector grommets 50 that have pins 10 installed in them.
- a connector holder 40 and a guide fixture 70 may accommodate three connector grommets.
- the guide fixture 70 may have openings 74 for the solder preforms to fit through, which are held in alignment with the connector pins 10 , so that only one solder preform will fit through each opening 74 .
- the fixture 70 is held in a registered position above the connector holder 40 by alignment pins 42 .
- an example method includes the steps of placing a large quantity of preforms 30 in a fixture comprising the connector holder 40 , connector grommets 50 , and guide fixture 70 . This overall assembly is then placed on a shaker table, and with a few strokes of a brush to sweep the preformed solder members 30 over the preform openings 74 , the preformed solder members will relatively quickly drop through the openings 74 and into all the connector pins 10 in the connector grommets 50 .
- the guide fixture 70 can be separated from the connector holder 40 , and the connector holder 40 can be used to further complete the process.
- the connector holder 40 can be positioned under a press, and a press plate 60 can exert pressure on the tops of the preforms 30 to force them fully into the cavities 20 in multiple connector pins (for example, all the pins in three connectors at a time).
- the preformed solder members 30 can deform and, because they have a volume that is essentially the same as that of the cavity, will completely, or substantially completely, fill the cavities 20 in the connector pins 10 . This process is aided by the fact that solder is considerably softer than the metal from which each connector pin is made.
- an example connector pin 10 suitable for use with a preformed solder member 30 generally comprises a first end 12 and a second end 14 of the pin, with an elongated portion 16 proximate the second end 14 , the elongated portion 16 typically of the configuration to mate with another connector.
- the connector pin 10 may be made of any metal with suitable electrical and mechanical properties for use in connectors, such as copper, brass, steel, palladium, or alloys of various metals.
- the connector pin 10 may be made of a single metal, an alloy, or have an alloy base (such as a copper alloy base) and be plated with another metal, such as gold or nickel.
- the connector pin 10 may comprise an upper portion 18 proximate the first end 12 .
- the connector pin 10 may further comprise a cavity 20 extending into the first end 12 toward the second end 14 , the cavity 20 comprising an opening 22 proximate the first end 12 .
- the upper portion 18 may be configured to receive a wire, specifically, once solder has been inserted into the cavity 20 , it can be used to solder a conductive wire to the pin.
- the elongated portion 16 of the connector pin may be either a male or female type connector element, and may thus mate with a complementary connector type.
- the connector pin's elongated portion 16 may comprise a first cylindrical section and the upper portion 18 may comprise a second cylindrical section, wherein the second cylindrical section has a greater diameter than the first cylindrical section.
- the first cylindrical section may comprise substantially the entire length of the elongated portion. It is also possible for the upper portion 18 and the elongated portion 16 to have the same diameter, which is often (but not always) the case with female type connector pins.
- the opening 22 is the only opening in the upper portion 18 of the connector pin 10 .
- This is not usually the case with solder-type connector pins, for the following reason:
- air is often trapped within the cup. Air trapped within cavities in solder pins is undesirable, because the air can expand rapidly when the solder is subsequently heated and melted. Avoiding this situation is typically done by the placement of a small weep hole toward the bottom of a solder cavity to allow air to escape. A weep hole is not necessary with the example embodiments described herein. Because the preformed solder members 30 are pressed into place, the cavity 20 of the connector pin may be substantially free of voids once the preformed solder member 30 is inserted and installed.
- the connector pin cavity 20 in the upper portion 18 of the pin, may also comprise a main portion 24 that is cylindrical and coaxial with the second cylindrical section, as would be created by drilling the pin to create the cavity 20 .
- the end of the cavity 20 opposite the opening may have different shapes, as dictated by design or simply as a result of how the cavity 20 is formed.
- the preformed solder member 30 will take the shape of the cavity 20 (including the taper portion), and fill it, when the solder member 30 is inserted and pressed into place. To accomplish this filling, the preformed solder member 30 will preferably have the same volume, or very nearly the same volume, as the cavity 20 , regardless of the cavity's shape.
- the preformed solder members 30 generally comprise a first end 32 , a second end 34 , and a sidewall 36 .
- the solder member 30 may be cylindrical, and dimensioned to fit within the cavities 20 of the connector pins of the example embodiments as shown in FIG. 1A .
- the preformed solder members are preferably formed without bends, burrs or deformations, so that they fit within the cavities 20 . For example, wound solder can first be straightened and then cut with a blade.
- the preformed solder members 30 may typically extend above the top surfaces 19 of the connector pins 10 , supported, for example, by the taper portion 26 of the cavity.
- the solder members may extend, for example, about 12% to about 15% above the top of connector pin surface 19 before being pressed into place.
- the preformed solder members 30 may be very close in volume to the volume of the cavity 20 in the connector pins they are to be installed in. As a result, if the solder members 30 are pressed firmly into place in the cavities, the result will be that the preforms fill the cavities substantially free of air voids within the cavity, since the softer solder will deform and take the shape of the cavity when under pressure.
- the drawings are not necessarily to scale, different lengths and diameters of preformed solder members may be used.
- the preformed solder members 30 may be made with many solder alloys, such as environmentally safe alloys (e.g., tin, silver, & copper), or tin and lead alloys as well.
- environmentally safe alloys e.g., tin, silver, & copper
- tin and lead alloys as well.
- the preformed solder-in-pin system is first created by inserting multiple precision-cut preformed solder members 30 into connector pins 10 for which they are designed. As discussed, different lengths and diameters of preformed solder members can be used, with connector pin cavities 20 sized and shaped accordingly to accommodate the preforms.
- multiple preformed solder members 30 can be inserted into multiple connector pins 10 in a highly efficient manner, operating on multiple pins at once, rather than inserting and compressing the preformed solder members in place one at a time.
- multiple connector pins 10 can be installed into a connector grommet 50 , of the type that will hold the pins in position when a connector is fully assembled (i.e., the grommet and pins are part of the assembled connector). This subassembly of a connector is best shown in FIG. 5 .
- the method involves using a connector holder 40 and a guide fixture 70 that is aligned just above the connector grommets 50 that have pins 10 installed in them.
- a connector holder 40 may be configured to hold three connector grommets 50 , with pins 10 installed, in place.
- the connector holder 40 may have alignment pins 42 positioned for indexing as described herein. As an example, multiple grommets/pins can be processed at once.
- a guide fixture 70 having the same size and shape, generally, as the connector holder 40 , may be used in installing preformed solder members 30 in multiple connector pins 10 . More specifically, in an example embodiment, the guide fixture 70 may be positioned above a connector holder 40 , and held in precise register with alignment holes 72 into which the alignment pins 42 of the connector holder 40 will fit. So assembled, the entire assembly may be placed on a shaker table as shown in FIG. 8 .
- the guide fixture 70 has multiple preform openings 74 , as best shown in FIGS. 7 and 11 , which are aligned with the installed connector pins 10 in grommets 50 . Only one solder preform 30 will fit through each opening 74 , but the openings 74 are sized so that the preforms 30 will easily fit and thus readily drop into place in the positioned pins 10 . Once in place on a shaker table, a very large number of preformed solder members 30 are placed on the guide fixture 70 , and the shaker table is turned on so that the members 30 will also vibrate freely (see, e.g., FIG. 9 ).
- each preform 30 will extend above the top surface of each pin, typically by about 12-15%, but this amount will of course vary depending on the chosen dimensions of the pin cavities 20 and the preformed solder members 30 .
- the guide fixture 70 can be separated from the connector holder 40 , and the connector holder 40 can be used to further complete the process.
- the connector holder 40 can be positioned under a press, as shown in FIGS. 4A-B and 12 - 13 , and a press plate 60 can exert pressure on the tops of the preforms 30 to force them fully into the cavities 20 in multiple connector pins (for example, all the pins in three connectors at a time).
- the preformed solder members 30 will deform and, because they have a volume that is essentially the same as that of the cavity, will completely, or substantially completely, fill the cavities 20 in the connector pins 10 , as best shown in FIG. 4B , where the voids that existed before the pressing operation (shown in 4 A) are no longer present. This process is aided by the fact that solder is considerably softer than the metal from which each connector pin is made.
- the resulting connector assembly can then have wires soldered to the connector pins 10 by, for example, melting the solder and inserting wires while it is still molten, resulting in the assembly shown in FIG. 14 , comprising the grommet 50 , connector pins 10 , and one or more wires corresponding to each connector pin. Because the preformed solder members are pressed, rather than melted, into place in the pins 10 before attaching wires, the solder only needs to be melted once to make a complete connector, which is desirable because solder can degrade each time it is melted, and prolonged periods at higher temperatures can also cause dissolution of the base material of the connector pins.
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
Abstract
Description
Claims (19)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US17/321,745 US11404838B2 (en) | 2019-03-08 | 2021-05-17 | Preformed solder-in-pin system |
US17/873,423 US12034263B2 (en) | 2019-03-08 | 2022-07-26 | Preformed solder-in-pin system |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US16/297,116 US10886685B2 (en) | 2019-03-08 | 2019-03-08 | Preformed solder-in-pin system |
US17/139,279 US11050206B2 (en) | 2019-03-08 | 2020-12-31 | Preformed solder-in-pin system |
US17/321,745 US11404838B2 (en) | 2019-03-08 | 2021-05-17 | Preformed solder-in-pin system |
Related Parent Applications (1)
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US17/139,279 Continuation US11050206B2 (en) | 2019-03-08 | 2020-12-31 | Preformed solder-in-pin system |
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Application Number | Title | Priority Date | Filing Date |
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US17/873,423 Continuation US12034263B2 (en) | 2019-03-08 | 2022-07-26 | Preformed solder-in-pin system |
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US20210273393A1 US20210273393A1 (en) | 2021-09-02 |
US11404838B2 true US11404838B2 (en) | 2022-08-02 |
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US17/139,279 Active US11050206B2 (en) | 2019-03-08 | 2020-12-31 | Preformed solder-in-pin system |
US17/321,745 Active US11404838B2 (en) | 2019-03-08 | 2021-05-17 | Preformed solder-in-pin system |
US17/357,430 Active US11695244B2 (en) | 2019-03-08 | 2021-06-24 | Preformed solder-in-pin system |
US17/873,423 Active 2039-10-13 US12034263B2 (en) | 2019-03-08 | 2022-07-26 | Preformed solder-in-pin system |
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US17/873,423 Active 2039-10-13 US12034263B2 (en) | 2019-03-08 | 2022-07-26 | Preformed solder-in-pin system |
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Cited By (1)
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US20220368095A1 (en) * | 2019-03-08 | 2022-11-17 | Onanon, Inc. | Preformed Solder-in-Pin System |
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US20220368095A1 (en) * | 2019-03-08 | 2022-11-17 | Onanon, Inc. | Preformed Solder-in-Pin System |
US12034263B2 (en) * | 2019-03-08 | 2024-07-09 | Onanon, Inc. | Preformed solder-in-pin system |
Also Published As
Publication number | Publication date |
---|---|
US20220368095A1 (en) | 2022-11-17 |
US20210320468A1 (en) | 2021-10-14 |
US10886685B2 (en) | 2021-01-05 |
US20200287341A1 (en) | 2020-09-10 |
US20210126416A1 (en) | 2021-04-29 |
US11050206B2 (en) | 2021-06-29 |
WO2020185216A1 (en) | 2020-09-17 |
US20210273393A1 (en) | 2021-09-02 |
US12034263B2 (en) | 2024-07-09 |
US11695244B2 (en) | 2023-07-04 |
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